Active bolster mounting system
An active bolster system for a vehicle includes a trim substrate panel adapted to be mounted to a structural element of the vehicle, wherein the substrate panel has a bolster opening. A bolster has a main body configured to fit within the bolster opening, wherein the main body has an A-side substantially flush with the substrate panel and a B-side facing the structural element. The main body has a plurality of lateral side tabs extending from the main body, and the main body expands during a deployment of the active bolster system so that a distance between the A-side and B-side increases. A retainer bracket retains the bolster against the substrate panel, wherein the retainer bracket comprises a frame extending around a periphery of the main body. The frame includes a reaction surface disposed against at least a portion of the B-side, a plurality of pinch tabs each pressing a respective lateral side tab against the substrate panel, and a plurality of rigid attachments for directly attaching the is retainer bracket to the substrate panel. Reaction forces applied by the bolster against the reaction surface during at least an initial expansion of the main body during the deployment are transmitted by the retainer bracket to the substrate panel so that separation is urged between the main body and the substrate panel, and the substrate panel is urged against the structural element.
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Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCHNot Applicable.
BACKGROUND OF THE INVENTIONThe present invention relates in general to active bolsters for automotive crash protection systems, and, more specifically, to a system for retaining an active bolster within an interior trim panel.
In order to reduce loads applied to an occupant from impact during a vehicle crash, active bolster systems are sometimes deployed within a vehicle interior. They may be located in an instrument panel or glove box door to protect the knees or in a door panel, window pillar, or seat structures to protect against side impacts. A typical active bolster is formed from a plastic material shaped into a bellows configuration on one surface. Upon the occurrence of a crash event of sufficient magnitude, an inflator is activated to inflate the bolster and expand the bellows to create an impact cushion.
An active bolster assembly requires a mounting that ensures a proper orientation and support during a deployment toward the occupant. It must be mounted to ensure that it deploys without any obstructions or misalignments that could degrade its trajectory or performance, and preferably not produce forces that would dislodge the trim panel from its mounting to an underlying structural element. Moreover, the appearance of the bolster itself and the fit with surrounding trim must meet craftsmanship specifications such as gap size, gap consistency, and flushness.
An active bolster is typically mounted to a fixed structural element of the vehicle in order to support the bolster against expansion and to receive the forces applied against the bolster during impact with an occupant. In the case of an active side impact system, the bolster may be mounted to a door frame. A door trim substrate panel is also mounted to the door frame to provide the interior surface of the door. The trim substrate panel includes an opening for receiving the bolster, and the bolster has an outer surface with a desired color and texture to match the trim panel. With both the bolster and trim substrate panel independently mounted to the door frame, it can be a challenge to accurately control placement of the bolster within the opening so that the gap has a constant width around the periphery and so that the A-surface flushness (i.e., matching the depth of the outer surfaces) has the desired appearance. A misalignment of the bolster with the opening may introduce interference between an is expanding bolster and the trim substrate panel which could cause the substrate panel to dislodge from its installed position or the breakage of a portion of the substrate panel from the assembly.
SUMMARY OF THE INVENTIONThe present invention employs a bracket for mounting a bolster directly to a trim panel so that the gap and flushness of the interface between the bolster and trim panel are well controlled. A high quality of pre-deployment appearance and deployment performance are achieved. Moreover, the active bolster is not directly mounted to the underlying vehicle structural component so that the forces created by the bolster during the initial inflation of the bolster before impacting an occupant help keep the trim panel from becoming dislodged.
In one aspect of the invention, an active bolster system is provided for a vehicle. A trim substrate panel is adapted to be mounted to a structural element of the vehicle, wherein the substrate panel has a bolster opening. A bolster has a main body configured to fit within the bolster opening, wherein the main body has an A-side substantially flush with the substrate panel and a B-side facing the structural element. The main body has a plurality of lateral side tabs extending from the main body, and the main body expands during a deployment of the active bolster system so that a distance between the A-side and B-side increases. A retainer bracket retains the bolster against the substrate panel, wherein the retainer bracket comprises a frame extending around a periphery of the main body. The frame includes a reaction surface disposed against at least a portion of the B-side, a plurality of pinch tabs each pressing a respective lateral side tab against the substrate panel, and a plurality of rigid attachments for directly attaching the retainer bracket to the substrate panel. Reaction forces applied by the bolster against the reaction surface during at least an initial expansion of the main body during the deployment are transmitted by the retainer bracket to the substrate panel so that separation is urged between the main body and the substrate panel, and the substrate panel is urged against the structural element.
A bolster of the present invention is comprised of a hollow chamber which may be blow molded as a single unit or injection molded in separate parts that may be welded together to form a hermetically sealed chamber. One surface of the chamber provides an A-side as a continuous “Class A” passenger-facing surface of a door panel, for example. The B-side the bolster is mounted to face a structural element of a vehicle such as an internal door frame.
An active bolster may be attached to a trim substrate panel using a retainer bracket 10 as shown in
Rigid attachment of retainer bracket 10 to a trim substrate panel is provided using mounting plates 14 with respective through holes 15. Extending outwardly from frame 11 are a plurality of pinch tabs 16. As also seen in the side view of
As also shown in the top view of
Claims
1. An active bolster system for a vehicle, comprising:
- a trim substrate panel adapted to be mounted to a structural element of the vehicle, wherein the substrate panel has a bolster opening;
- a bolster having a main body configured to fit within the bolster opening, wherein the main body has an A-side substantially flush with the substrate panel and a B-side facing the structural element, wherein the main body has a plurality of lateral side tabs extending from the main body, and wherein the main body expands during a deployment of the active bolster system so that a distance between the A-side and B-side increases; and
- a retainer bracket for retaining the bolster against the substrate panel, wherein the retainer bracket comprises a frame extending around a periphery of the main body, the frame including a reaction surface disposed against at least a portion of the B-side, a plurality of pinch tabs each pressing a respective lateral side tab against the substrate panel, and a plurality of rigid attachments for directly attaching the retainer bracket to the substrate panel;
- wherein reaction forces applied by the bolster against the reaction surface during at least an initial expansion of the main body during the deployment are transmitted by the retainer bracket to the substrate panel so that separation is urged between the main body and the substrate panel.
2. The system of claim 1 wherein the lateral side tabs and the pinch tabs are sufficiently flexible so that they deform during the deployment.
3. The system of claim 2 wherein each pair of a lateral side tab and a respective pinch tab initially extend substantially perpendicular to each other and then deform toward becoming parallel during the deployment.
4. The system of claim 1 wherein the trim substrate panel is comprised of a plurality of pinch pads spaced around the bolster opening, wherein each lateral side tab is pinched between a respective pinch pad and a respective pinch tab.
5. The system of claim 1 wherein the trim substrate panel includes a plurality of mounting posts spaced around the bolster opening, wherein the retainer bracket includes a plurality of mounting plates, and wherein each mounting plate is attached to a respective mounting post by a respective fastener.
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Type: Grant
Filed: Aug 29, 2011
Date of Patent: Nov 13, 2012
Assignee: Ford Global Technologies, LLC (Dearborn, MI)
Inventors: Michael G. Orlowsky (Sterling Heights, MI), Raymond E. Kalisz (Livonia, MI)
Primary Examiner: Drew Brown
Attorney: MacMillian, Sobanski & Todd, LLC
Application Number: 13/219,787
International Classification: B60R 21/206 (20110101);